| 09 - HAZMAT Substitutions |
Batteries-Management
Global Positioning System units are currently equipped with lithium batteries. Lithium batteries pose a safety hazard and must be disposed of as a hazardous waste. For these reasons, it was decided that lithium batteries would no longer be used. FASTT recommends using Nickel-Hydride batteries as a replacement. These are safer than the lithium batteries and maintain a charge 2 to 3 times longer than alkaline batteries. Lead acid rechargeable batteries were also recommended for training exercises.
Unit is currently using lithium batteries in their communication equipment. These batteries are for single use and are disposed of a hazardous waste. Sealed lead acid rechargeable batteries are recommended to replace the lithium batteries in training exercises. This would provide significant savings in disposal cost because the lead acid batteries can be recycled.
Nickel-cadmium batteries are used for emergency lighting. Ni-Cad batteries develop memories when activated for short periods of time and lose their operational life, therefore losing effectiveness and requiring disposal as hazardous waste. FASTT recommends the use of sealed gel-filled lead acid batteries. These batteries have a long life span because they have no memories. They can also be recycled after use, eliminating the need to dispose of batteries as hazardous waste.
Various training exercises use a large number of lithium batteries that are discarded as hazardous waste after a single use. These batteries can be replaced with sealed second generation lead acid rechargeable batteries (good for 300-400 cycles). The lead acid batteries hold a charge for approximately 10 hours and have been proven in field activities. Total first year savings would amount to $12,000.
Note
Team notes accomplishments of AFDM14. Hazmat coordinator established an internal control system for HM control and HW management, reducing waste stream to a minimum.
SIMA machine shop has devised a portable coolant unit used for machining operations requiring only small quantities of coolant. The unit is applicable for field and remote machining operations with compressed air supply. This is an exportable technology.
Substitute/1,1,1-Trichloroethane
FASTT identified 9 opportunites for workshops to phase out use of 1,1,1 Trichloroethane. 2 examples follow:
1,1,1 Trichloroethane (a restricted material being phased out of production) is used to prepare (degrease) cable ends for zinc casting. Using an already available sonic parts cleaner along with a non-hazardous solvent substitute may rid process of 1,1,1 Trich.
Shop uses 1,1,1-Trichloroethane solvent to clean circuit cards after they are tested for defects. 1,1,1-Trichloroethane is an ODS and a health hazard, and is no longer manufactured in the US. The shop will be required to find a replacement solvent. FASTT recommends isopropyl alcohol.
Substitute/Acetone
Acetone is used to remove carbon from heat-treated valves. A safer alternative should be used. FASTT recommends two products, Skysol 100 (NSN 6850--01-381-4423) and Vortex (NSN 6850-01-386-8405). Shop 11A uses acetone to clean welds prior to NDT. Acetone has a low flash point and minor TLV problems. As it is used for just this one process the FASTT Team recommends using a water based material.
Substitute/Asbestos
Shop removes gaskets from P-250 heads. Since many of the gaskets contain asbestos material, it is assumed that all gaskets contain asbestos and all are handled as such. Opportunity exists for replacing these gaskets with ones that do not contain asbestos. Existing gaskets can also be tested to determine if they do indeed contain asbestos. Non-asbestos containing gaskets can be disposed of as regular solid waste.
Substitute/Carbon
Shop uses 55-gallon carbon cartridges to pre-treat rinse water. Two drums are Cartridges disposed of each month as hazardous waste. FASTT recommends eliminating use of the carbon cartridges and using a non-hazardous material, thus dramatically reducing the amount of hazardous waste being generated in the shop.
Substitute/CFC-113
Gage cleaning is currently performed per military specifications using CFC-113 solvent, a Class I ODS. NAVSEA 03Y2A is in the process of approving a substitute for CFC-113. The substitute material, HFE 7100, should be approved by the end of 1997. Using this material would significantly reduce hazardous waste disposal costs for the shop.
Substitute/Cleaning Solution
Current ultrasonic cleaner uses a toxic cleaning solution that requires full PPE and is run at a high temperature. FASTT recommends the use of Daraclean 282GF (glycol free) as a replacement. Daraclean 282GF contains less SARA Title III chemicals and can be used at safe operating temperatures. Additionally, less PPE is required.
Substitute/Coolant
A coolant is currently used in a machine shop that has been reported to cause skin irritation. FASTT recommends a less hazardous coolant that is being used at Puget Sound Naval Shipyard that has no known health effects and that has a higher fire code rating.
Substitute/Cutting Fluid
Shop 31A contains over 40 pieces of equipment used to machine and repair parts. A water soluble cutting fluid (VV-G-846A) is used in all of the machines. This fluid cannot be recycled and becomes rancid after a short period of time. Used cutting fluid must be removed and replaced periodically per PMS cards. Use of a recyclable cutting fluid, such as BLASOCUT 2000 CF, could reduce wastes by as much as 90%. Because this fluid can be reused several times, purchasing and disposal cost would be reduced, resulting in an annual savings of $12,829.
Substitute/Cutting Fluid
Machine shop personnel use machines requiring certain types of fluids to aid in metal fabrication. There have been complaints that the currently specified cutting fluid, VV-846, Type I does not provide the properties normally associated with machine cutting fluids. FASTT recommends the use of Blasocut 2000CF, which is currently being used at another activity with positive results. This material is not only a superior product, but it is recyclable.
Cutting fluid specified for lathes, etc., is a skin irritant and has a short useful life. It is disposed of as a hazardous waste. Better cutting fluids (less hazardous and longer lasting) are on the commercial market. FASTT will attempt to work with Naval Supply system to get better quality, recyclable cutting fluids into the system.
Substitute/Degreaser
Several Public Works locations use a contractor that employs hand cleaning and a low flashpoint solution (Super Agitene) in machine shops. FASTT recommends use of PF Degreaser which has a higher flash point.
Many shops use cold solvent cleaners for various cleaning operations that are filtered and circulated through the system and at the end of their service life, they are containerized and disposed of. FASTT recommends substituting a highly refined aromatic hydrocarbon, PF Degreaser, which will provide all of the cleaning benefits at a greatly reduced cost.
Shop currently uses a solvent degreaser unit provided by Safety Kleen for parts degreasing. Shop personnel are concerned that this solvent may not meet the requirements of P-D-680, and that they may need to resort to hand cleaning with the appropriate solvent. FASTT recommends the continued use of the Safety Kleen solvent washers,provided it is utilizing P-D-680. Environmental Affairs is to verify that the solvent used in the Safety Kleen equipment meets the requirements of P-D-680.
Substitute/Detergent
Shop currently utilizes two aqueous parts washers. The detergent used for these is issued in powdered form. Addition of the detergent to the aqueous parts washer is a slow and unpredictable process. Also, the concentration of the detergent cannot be determined after initial makeup. This results in needless disposal of detergent. An approved detergent exists that allows for precise additions to be made by personnel. A titration unit enclosed with the detergent can be use to determine the detergent concentration. The detergent also has a rust inhibitor which prevents flash rusting of components as well as the parts washer itself. FASTT will provide technical data for the substitute detergent.
An aqueous parts washer is used to clean P-3 wheels and bearings. The detergent that is used does not include a rust inhibitor. Using a detergent that includes a rust inhibitor would increase the life of the washer and decrease flash rusting of the parts being cleaned. The need to rewash parts would be eliminated, resulting in man-hour saving. A test kit included with the detergent would allow the artisan to check the concentration on a regular basis, and would promote extending the life of the solution.
Substitute/Disinfectant
Shop disinfects diving gear and mouthpieces after each use. Various types of disinfectants are used for the different parts of the dive gear. A universal disinfectant could be used for all pieces of the dive gear, reducing the amount of materials needed, as well as the waste streams.
Substitute/Ethanol
Currently ethanol, acquired through special purchase, is used to clean printing from aluminum and rubber pieces prior to fabrication. FASTT Team found denatured alcohol to work equally as well at an approximate cost savings of $185 per year.
Substitute/Leaded Compounds
Shop uses various greases, oils and cleaning compounds when repairing weapons, such as "Led-Plate" anti-seize compound (MIL-A-907E, NSN 8030-00-251-3980), which contain lead. Use of a non-leaded substitute for the anti-seize compound is recommended. FASTT will provide a viable alternative.
Maintenance of lead wire throughout the floating DD requires use of lead-based grease and hazardous solvents for cleaning. Use of lead-free wire rope grease will be allowed under an upcoming amendment to MIL-G-18458. Solvents to replace the hazardous one currently used have been specified by NAVSEA.
Steal Guard Tech 1301, NSN 8030-01-059-5478, is used as a corrosion preventative in MK48 engines. This preventative contains lead, which creates potential health problems and limits potential recycling options. The Steel Guard Tech 1301 can be substituted with Steel Guard Tech-No Lead, product number 1301-NL, NSN 8030-01-059-5478. This is available in the Navy Stock system and is approved for use.
Wire rope used for heavy equipment is lubricated with MIL-G-18458 grease. Shipyards have found this grease contains lead and therefore creates waste disposal problems. OPNAVINST 5100.23D establishes controls on occupational and environmental exposure to lead by substitution where possible. The forthcoming amendment to MIL-G-18458 will provide an opportunity to eliminate the use of heavy metals such as lead in future formulations.
Substitute/MEK
MEK is used on cotton swabs to check for completed cure of powder coating after removal from cure oven. SIMA is currently using about one pint per year; however, MEK is a VOC that the SIMA will no longer be able to use. DS-108 wipe solvent has been utilized by several DOD facilities as a suitable replacement for MEK in many applications. Action brings no cost savings.
Substitute/MEK and Toluene
MEK and toluene are used to repair rubber boats (both restricted solvents). This is an opportunity to use Prototype DS-108.
Substitute/Methylene Chloride
Future plans to eliminate the use of methylene chloride (for tank stripping) includes implementing the use of an environmentally-friendly product, X-Caliber. X-Caliber is not currently approved as a chemical paint remover under NAVAIR 01-1A-509. However, several products have been approved, including FO606, which FASTT recommends using instead of X-Caliber.
Work center uses MIL-R-81294 for manual paint stripping of components too large for glove boxes, but too light for sand blasting in a walk-in booth. MIL-R-81294 is a methylene chloride, phenolic mix stripper that is a known carcinogen and is extremely harmful to personnel. FASTT recommends replacing MIL-R-81294 with MIL-R-83936 for tank dipping or open purchase of TURCO 6813 for manual stripping. Both substitutions are free of methylene chloride and phenols. Shop uses methylene chloride to remove head gasket residue. OMC Marine manual requires the solvent use. Substance is a carcinogen and is disposed of as a hazardous waste. Could be substituted with a non-hazardous material such as isopropanol.
Substitute/PD-680
FASTT made 6 recommendations concerning use of P-D-680. 5 examples follow:
Workcenter had been using FB 245 to clean wheel bearing but this solvent caused flash rusting. The shop switched to P-D-680. FASTT recommends PF degreaser, which is cheaper and safer than the other two, as a substitute solvent.
A hydraulic shop tests hydraulic components and services equipment using P-D-680 Type I as a solvent. FASTT Team recommends substituting P-D-680 Type III because of it's higher flash point and lower concentrations of aromatic hydrocarbons. An improved work environment would result.
Small engine repair shop uses P-D-680 Type I cleaner. FASTT Team recommends substituting P-D-680 Type III cleaning solution to improve personnel safety, decrease potential fire hazard because of higher flash point, and decrease disposal costs because Type III does not generate a hazardous waste.
Shop uses a tank filled with P-D-680, type II solvent to clean bearings and small parts. Solvent is periodically removed from the shop as hazardous waste. Formula 724 solvent could be used, no reduction in waste stream but the solvent has a higher flash point and is safer for the user.
P-D-680 is a flammable and toxic solvent used to flush/clean target motors after they have been used. Approximately 970 pounds of P-D-680 is used per year. FASTT is currently working with the cognizant technical office to determine if P-D-680 is a specification requirement and if a comparable, safer alternative can be utilized. One possibility is Biotek's 134-HI-SOLV, which has been approved by NAVSEA and NEHC as a substitute for specific cleaning operations.
Substitute/Sealing Compounds
Workshop currently uses a sealing compound that contains carcinogenic toxins. Replacement of this compound with a safer alternative is recommended. FASTT is currently researching substitute compounds that will fulfill the requirement of the currently used compound.
Substitute/Xylene and Butyl Alcohol
Shop is planning to use an available solvent that contains xylene and butyl alcohol for its paint gun waster units. It is recommended that this solvent be replaced with a less hazardous one, such as Ecolink, Inc., Safe Strip (NSN 6850-01-386-8428).
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